Milk crate

ABSTRACT

Four embodiments of a tray are disclosed for transporting and storing milk containers and for nesting the trays for their return trip to their origin.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 15/019,642 filed Feb. 9, 2016, which claims the benefit of U.S. Provisional Application No. 62/114,176 filed Feb. 10, 2015, the contents of which are incorporated herein by reference.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The present invention relates to crates and trays for supporting product during transit, storage, and display and, in particular, trays for supporting bagged milk or plastic/paper containers of milk.

BACKGROUND

Milk is normally delivered to the point of purchase either in plastic containers (bottles) or in plastic bags. Plastic bottles have recently been delivered to wholesale outlets in pallet quantities by using unique bottles and corrugated layer pads. The bottles and pads have been designed to support the weight of the bottles in a stack for delivery. Up to this point, bagged milk has only been able to be shipped in large quantities using metal dollies or shelves that can support the entire product weight. These shelving units are generally bulky and do not collapse well. In addition, the bagged milk tends to display poorly with the individual bags leaning off the shelves and looking disheveled.

SUMMARY OF THE INVENTION

The present invention creates a nestable tray or crate system that supports the weight of the bottled or bagged milk.

The trays condense for return shipping by nesting into one another. The trays also provide complete support for the containers' weight as well as provide for better display customer presentation.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings and attachments in which:

FIG. 1 is a perspective view of the tray of the first embodiment of the present invention;

FIG. 2A is a side view of the tray of FIG. 1 in operation;

FIG. 2B is a side elevation of a single tray of FIG. 1;

FIG. 3 is a side view of the tray of FIG. 1 nesting;

FIG. 4A is a perspective view of the tray of the second embodiment stacked and in use;

FIG. 4B is a perspective view of the tray of FIG. 4A nesting;

FIG. 5 is a top plan view of the tray of FIG. 4;

FIG. 6 is a side elevation view of the tray of FIG. 4;

FIG. 7 is a view showing three separate stacks of the trays of FIG. 4 with product;

FIG. 8A is a perspective view of the tray of the third embodiment stacked and in use;

FIG. 8B is a perspective view of the tray of FIG. 8A nesting;

FIG. 9 is a top plan view of the tray of FIG. 8;

FIG. 10 is a side elevation view of the tray of FIG. 8;

FIG. 11 is a view showing three separate stacks of the trays of FIG. 8 with product;

FIG. 12A is a perspective view of the tray of the fourth embodiment stacked and in use;

FIG. 12B is a perspective view of the tray of FIG. 12A nesting;

FIG. 13 is a top plan view of the tray of FIG. 12;

FIG. 14 is a side elevation view of the tray of FIG. 12; and,

FIG. 15 is a view showing three separate stacks of the trays of FIG. 12 with product.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

First Embodiment

A first embodiment of the tray 10 is shown in FIGS. 1-3. Each tray 10 includes a top surface 11 and bottom surface 12, opposed sides 22, and opposed ends 23. Looking at the top surface 11 of the tray 10, it 10 has a plurality of parallel flat surfaces 14 and a plurality of troughs or channels 15. Each trough 15 includes inwardly tapered or inclined walls 18,19 and a substantially flat seating floor 20. The flat surfaces 16,17 forming the sides 22 of the tray 10 are the same width.

As shown in FIG. 2B, the underside or bottom surface 12 of the tray 10 has the reverse contours of the upper surface 11 of the tray 10. The surfaces 11,12 are complementary of each other. Whereas a trough 15 is in the top surface 11, a flat surface 14 is on the bottom surface 12 and visa versa.

This configuration permits the milk bags M to be placed and lined-up next to one another in the troughs 15. FIG. 1. When trays are placed confronting one another (flat surfaces 14 of the bottom surface 12 of the upper tray touching the flat surface 14 of the top surface 11 of the lower tray and the trough 15 of the bottom surface of the upper tray facing and aligned with the trough 15 of top surface 11 of the lower tray), or facing one another, they form enclosed honeycomb spaces or vertical pockets 50 for both seating and protecting the milk M placed therein. FIG. 2. The troughs 14 on the underside 12 of the tray 10, form the upper portion the pockets 50 formed therein below for the milk bags M. And, when the trays 10 are stacked in the same direction, they nest within one another and are seated one on top of the other. FIG. 3.

Trays may also be injection molded, made of structural foam, or made by single sheet thermoformed. The tray 10 is approximately 98″ (end 23) by 40″ (side 22). The troughs 15 have a total width of 6″.

The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in FIG. 3.

In another variation of this embodiment, The flat surfaces 16,17 forming the sides 22 of the tray 10 are of different widths such that rather than confronting the trays for storing milk, one of the trays is rotated 180 degrees and stacked upon another tray. This arrangement is discussed more fully below with respect to the other embodiments.

Second Embodiment

The second embodiment of the tray 110 is shown in FIGS. 4-7. FIG. 4A shows the trays holding product M and FIG. 4B shows the trays empty and nested for storage or transport to their place of origin.

Each tray 110 includes a top or upper surface 111 and bottom surface 112, opposed sides 122, and opposed ends 123. The tray 110 has a checkerboard appearance, with a plurality of upper parallel flat surfaces 114 and a plurality of pockets 115. Each pocket 115 includes inwardly tapered or inclined walls 118 and a substantially flat seating floor 120. The underside or bottom surface 112 of the tray 110 has the reverse contours of the upper surface 111 of the tray 110. Again, the bottom surface 112 of the tray 110 is substantially complementary to the top surface 111.

This configuration permits the milk bags M to be placed in the individual pockets 115. FIGS. 5 and 6. When trays are positioned such that one tray confronts the adjacent tray so that flat surfaces 114 of the confronting trays 110 touch one another and the pockets 115 of the confronting trays face and align with one another, they form enclosed spaces or pockets 150 for both seating and protecting the milk M. FIG. 4A. When they are stacked in the same direction, they nest within one another. FIG. 4B.

In the alternative, this configuration permits the milk bags M to be placed in the individual pockets 115. FIGS. 5 and 6. When trays are positioned such that one tray is 180 degrees relative to the adjacent tray so that flat surfaces 114 of the bottom surface 112 of the upper tray touching the flat surface 114 of the top surface 111 of the lower tray and the pockets 115 of the bottom surface of the upper tray facing and aligned with the pockets 115 of the upper surface of the lower tray, or are facing one another, they form enclosed spaces or pockets 150 for both seating and protecting the milk M. FIG. 4A. The pockets 114 formed on the underside 112 of the tray 110, support the next row of milk bags M. And, when they are stacked in the same direction, they nest within one another. FIG. 4B.

The tray 110 further includes an outer continuous perimeter rim 133 around the entire tray which forms outer end lips 130 and outer side lips 131 to facilitate gripping and handling of the trays and add strength to the tray and lips.

Again, like the first embodiment, the trays 110 of the second embodiment are made of a rigid plastic, such as virgin or recycled HDPE (high density polyethylene), PP (polypropylene), and PE (polyethylene). Trays may also be injection molded, made of structural foam, or made by single sheet thermoformed. The tray 110 is approximately 20″ (end 123) by 48″ (side 122). The pockets 115 have a width of 9.2″ and a depth of 4.6″. The tray has a thickness of 6″ with the lip 130 being approximately 3.1″ from the top surface 111. This permits the storage and transportation of 10 milk bags M per layer.

The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in FIG. 7.

Third Embodiment

The third embodiment of the tray 210 is shown in FIGS. 8-11. FIG. 8A shows the trays 210 with product therein and in use and FIG. 8B shows the trays 210 empty and nested for storage or transport to their place of origin. As seen, the trays are all facing the same direction when nesting (FIG. 8B) and every other tray is rotated 180 degrees from the adjacent tray when storing product (FIG. 8A).

Each tray 210 includes a top surface 211 and bottom surface 212, opposed sides 222, and opposed ends 223. The tray 210 has a plurality of dividers 214 and a plurality of pockets 215 with a substantially flat seating floor 220.

The ends 223 of the tray 210 include a plurality of towers, or trapezoidal structures thereon having upwardly projecting towers 230 and downwardly projecting walls 231. The towers 230 have angular edges or surfaces 224 and a flat top 225 edge while the projecting walls 231 have angular edges 226 and a flat edge 240. In addition, a channel 244 for seating the tower 230 is formed in the tray by the edges 226 that terminates in a flat seat 227. The trapezoidal structures are offset so that the edges and flat portions mate or communicate with one another differently when stacked and nested. This is shown in FIG. 8A.

The towers 230 seat or are interconnected to the channels 244. Interconnecting knobs 258 are formed in the upper surfaces or flat top 225 of the towers 230 for fitting within corresponding indents 259 or openings in the flat top 244. This prevents sliding between the trays once aligned and seated.

The tray 210 is not symmetrical. As a result, the trays seat with each other or cooperate with one another differently when adjacent trays face the same way or face different ways (turned 180 degrees). This configuration permits the milk bags M to be placed and stored in the pockets 215 while the towers protect them and support the tray above them when every other tray is rotated 180 degrees (FIG. 8A).

Again, as with the prior embodiment, the trays 210 of the third embodiment are made of a rigid plastic, such as virgin or recycled HDPE (high density polyethylene), PP (polypropylene), and PE (polyethylene). Trays may also be injection molded, made of structural foam, or made by single sheet thermoformed.

The tray's dimensions are shown in the Figures. The tray is 24″ by 40″ with the pockets being 9.88″ by 9.14″. The tray has a height of approximately 6.1″ with the towers having a height of roughly 12.2″.

The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in FIG. 11.

Fourth Embodiment

The fourth embodiment of the tray 310 is shown in FIGS. 12-15. FIG. 12A shows the trays holding product M and FIG. 12B shows the trays empty and nested for storage or transport back to their place of origin.

Each tray 310 includes a top surface 311 and bottom surface 312, opposed sides 322, and opposed ends 323. The tray 310 has a plurality of parallel flat surfaces 314 a and dividers 314 b and a plurality of pockets 315 with a substantially flat seating floor 320. The underside or bottom 312 of the tray 310 can substantially have the reverse contours of the upper side 311, with or without dividers 314 b, of the tray 310.

This configuration permits the milk bags M to be placed in the pockets 315. When every other tray is stacked and rotated 180 degrees (flat surfaces 314 a of the lower surface 312 of the upper tray touching the flat surface 314 a of the upper surface 311 lower tray (rotated 180 degrees) and the pockets 315 of the upper tray facing and aligned with the pockets 315 of the lower tray), they form enclosed spaces or pockets for both seating and protecting the milk M. The pockets or chambers 350 formed therebetween. And, when the trays are stacked in the same direction, they nest within one another. FIG. 12B.

The tray 310 further includes an outer continuous perimeter rim 333 around the entire tray which forms outer end lips 330 and outer side lips 331 to facilitate gripping and handling of the trays and add strength to the tray and the lips.

The trays are made of a rigid plastic, as the prior embodiments and may also be injection molded, made of structural foam, or made by single sheet thermoformed. The tray's dimensions are shown in the Figures.

The tray's dimensions are shown in the Figures. The tray is 20″ by 48″ with the pockets being 4.4″ by 9.1″. The tray has a height of the tray is 6.5″.

The stacked, confronting trays are sized so they can be transported and stored on pallets P as shown in FIG. 15.

The terms “first,” “second,” “upper,” “lower,” “top,” “bottom,” “above,” below,” etc. are used for illustrative purposes to associate relative positioning of elements to other elements only and are not intended to limit the embodiments in any way. The term “plurality” as used herein is intended to indicate any number greater than one, either disjunctively or conjunctively as necessary, up to an infinite number. The terms “joined,” “attached,” and “connected” as used herein are intended to put or bring two elements together so as to form a unit, and any number of elements, devices, fasteners, etc. may be provided between the joined or connected elements unless otherwise specified by the use of the term “directly” and/or supported by the drawings.

While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims. 

I claim:
 1. A tray for use with a similar tray to form a tray stack for supporting individual containers, the tray having a first end and a second end opposed to the first end, an array of a plurality of alternating pairs of upper flat surfaces and downwardly extending pockets to define a checkerboard pattern, an outer continuous perimeter rim extends about the array, an axis of rotation extends perpendicular to the upper flat surfaces, the plurality of upper flat surfaces nest within the plurality of pockets of a similar tray when in a first orientation to form a nested stack of trays, and the plurality of flat surfaces contact a plurality of flat surfaces of a similar tray in a second orientation to form chambers for seating the containers therebetween, the second orientation being rotated 180° about the axis of rotation with respect to the first orientation.
 2. The tray of claim 1 wherein the containers do not support the stack.
 3. The tray of claim 2 wherein the pockets have tapered interior side walls and a flat bottom surface.
 4. The tray of claim 3 wherein the chambers have a height greater than a height of the containers.
 5. The tray of claim 4 wherein the tray is fabricated from a polymeric material.
 6. The tray of claim 5 wherein the polymeric material is selected from the group consisting of polyolefins, polyamides, and polyesters.
 7. The tray of claim 6 wherein the polyolefin includes homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same.
 8. The tray of claim 7 wherein the polyolefins include high density polyethylene, polypropylene, and polyethylene.
 9. The tray of claim 8 wherein the polymeric material is foamed.
 10. A tray for use with a similar tray to form a tray stack for supporting individual containers, the tray having a first end and a second end opposed to the first end, an array of a plurality of alternating pairs of upper flat surfaces and downwardly extending pockets to define a checkerboard pattern, the pockets having a tapered inner wall and a flat bottom surface, an outer continuous perimeter rim extends about the array, an axis of rotation extends perpendicular to the upper flat surfaces, the plurality of upper flat surfaces nest within the plurality of pockets of a similar tray when in a first orientation to form a nested stack of trays, and the plurality of flat surfaces contact a plurality of flat surfaces of a similar tray in a second orientation to form chambers for seating the containers therebetween, the second orientation being rotated 180° about the axis of rotation with respect to the first orientation.
 11. The tray of claim 10 wherein the containers do not support the stack.
 12. The tray of claim 10 wherein the chambers have a height greater than a height of the containers.
 13. The tray of claim 10 wherein the tray is fabricated from a polymeric material.
 14. The tray of claim 13 wherein the polymeric material is selected from the group consisting of polyolefins, polyamides, and polyesters.
 15. The tray of claim 14 wherein the polyolefin includes homopolymers and copolymers of ethylene, propylene, butene, hexene, octene and combinations of the same.
 16. The tray of claim 15 wherein the polyolefins include high density polyethylene, polypropylene, and polyethylene.
 17. The tray of claim 15 wherein the polymeric material is a high density polyethylene.
 18. The tray of claim 15 wherein the polymeric material is a polypropylene.
 19. The tray of claim 14 wherein the polymeric material is a polyester.
 20. The tray of claim 14 wherein the polymeric material is foamed. 